Steering grip light bar systems

ABSTRACT

Various implementations include a light bar system for a steering wheel of a vehicle that includes a high intensity light source, a light diffusing layer, and an outer lens. For example, in certain implementations, the light diffusing layer is disposed between a plurality of high intensity light emitting diodes (LEDs) and an outer lens, and the light diffusing layer causes the light from the LEDs to appear as a continuous stream of light across a length of the lens and provides sufficiently bright lighting to warn or communicate with the driver in various ambient lighting conditions. In certain implementations, the outer lens is colored to blend in with the rest of the steering wheel when the LEDs are not activated.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent ApplicationNo. 62/027,969, entitled “Steering Grip Light Bar Systems,” which wasfiled on Jul. 23, 2014, the content of which is herein incorporated byreference in its entirety.

BACKGROUND

Various advanced driver assistance systems incorporate visual, acoustic,and/or haptic warnings for drivers. Visual interfaces for these systemsshould minimize driver reaction time to warnings and the workload of thedriver to comprehend and respond to the warning or information.Conventional instrument panel and center-stack displays require thedriver's attention be drawn away from the navigating the vehicle.Similarly, idealized heads up displays can be jarring and sometimesdistracting to the driver.

Accordingly, there is a need in the art for improved systems and methodsof providing visual interfaces in vehicles.

BRIEF SUMMARY

Various implementations disclosed herein include a light bar system fora steering wheel (or grip) of a vehicle. The light bar system includes ahigh intensity light source and a light diffusing layer disposed on aportion of the steering wheel. The light from the light source isdiffused through the light diffusing layer, and the diffused light isemitted toward a driver or operator of the vehicle. For example, incertain implementations, the light bar system includes a plurality ofhigh intensity light emitting diodes (LEDs) disposed behind an outerlens, and the light diffusing layer is a film disposed between an innersurface of the outer lens and the LEDs. In other implementations, theouter lens may diffuse light on its own or in combination with one ormore light altering films. The light exiting the outer surface of theouter lens appears as a continuous stream of light across a length ofthe lens and provides sufficiently bright lighting to warn orcommunicate with the driver in various ambient lighting conditions. Incertain implementations, the outer lens is colored to blend in with therest of the steering wheel when the LEDs are not activated. The outerlens and/or one or more light altering films disposed between the outerlens and the LEDs prevent ambient light from entering the lens andilluminating the LEDs or components behind the lens, which reducesdistractions and the potential for false warnings or unintendedcommunications with the driver.

In particular, according to various implementations, a light bar systemfor a steering wheel includes at least one light emitting diode (LED)disposed adjacent a portion of an armature of a steering wheel, ahousing that defines a light optimizing channel, and a light diffusinglayer that has an inner surface and an outer surface. The lightoptimizing channel has a proximal end disposed adjacent the LED, and theinner surface of the light diffusing layer is disposed adjacent a distalend of the light optimizing channel. The light diffusing layer isconfigured for diffusing light as it passes through the layer from theinner surface to the outer surface. In addition, the light optimizingchannel may include a reflective surface that extends between theproximal and distal ends. In certain implementations, the lightdiffusing layer is configured to cause the light being diffused therethrough to appear as a continuous stream of light across the lightdiffusing layer.

For example, in some implementations, the light diffusing layer may be afilm coupled to an inner surface of an outer lens. An outer surface ofthe outer lens faces a driver (or operator) of the vehicle, and theinner surface of the lens is adjacent the distal end of the lightoptimizing channel. In certain implementations, the outer surface of theouter lens is configured for being disposed substantially flush with anouter skin of the steering wheel. The light bar system may also includeone or more additional light altering films disposed between the distalend of the light optimizing channel and the inner surface of the outerlens. The light altering film may include a brightness enhancing film, alight diffusing film, and/or a light turning film. For example, thelight altering film may include a light diffusing film and a brightnessenhancing film. The light diffusing film is disposed adjacent the lightoptimizing channel, and the brightness enhancing film is disposedadjacent the outer lens. As another example, the system may also includea light turning film that is disposed between the brightness enhancingfilm layer and the lens.

In various implementations, the outer lens may be at least partiallytranslucent and/or partially opaque. In other implementations, the outerlens may be at least partially transparent.

In some implementations, a light bar system for a steering wheelincludes at least one light source disposed adjacent a portion of anarmature of a steering wheel; and a light diffusing layer having a firstsurface and a second surface. The first surface of the light diffusinglayer is disposed adjacent the light source, and the light diffusinglayer is configured for diffusing light as light passes there throughfrom the first surface to the second surface such that the light exitingthe second surface appears as a continuous stream of light across thesecond surface of the light diffusing layer.

In various implementations, a light bar system for a steering wheelincludes at least one light source disposed adjacent a portion of anarmature of a steering wheel; and a light diffusing layer having aninner surface and an outer surface. The light is diffused as it passesthrough the light diffusing layer from the inner surface to the outersurface, and the inner surface of the light diffusing layer is spacedapart from the light source such that an air gap is defined between theinner surface and the light source. The light exiting the outer surfaceappears as a continuous stream of light across the outer surface.

BRIEF DESCRIPTION OF DRAWINGS

Various implementations of the system are described in detail inrelation to the following drawings. The drawings are merely exemplary toillustrate the structure of certain implementations. Certain featuresshown herein may be used singularly or in combination with otherfeatures. The invention should not be limited to the implementationsshown.

FIG. 1 is a perspective front view of the light bar system on a steeringwheel according to one implementation.

FIG. 2 is a cross-sectional view of the light bar system shown in FIG. 1taken along the A-A line.

FIG. 3 is a front view of a printed circuit board with a plurality oflight emitting diodes disposed thereon according to one implementation.

FIG. 4 is an exploded view of light altering films according to oneimplementation.

FIGS. 5A through 5D are views of various components of a light barsystem for a steering wheel according to another implementation.

FIG. 6 is a straight light optimizing channel according anotherimplementation.

FIG. 7 is a tapered light optimizing channel according to anotherimplementation.

FIG. 8 is a bent light optimizing channel according to anotherimplementation.

FIG. 9 is a front view of the light bar system on a steering wheelaccording to another implementation.

FIG. 10 is an exploded, partial view of the light bar system on asteering wheel according to another implementation.

FIG. 11 is an exploded, perspective view of the light bar system on asteering wheel according to another implementation.

FIG. 12 is a cross-sectional view of the light bar system on a steeringwheel according to another implementation.

FIG. 13 is a perspective view of the carrier of the light bar systemshown in FIG. 1.

FIG. 14 is a perspective view of the lens of the light bar system shownin FIG. 1.

FIGS. 15 through 17 are flow charts illustrating methods of assembling alight bar system to a steering wheel according to variousimplementations.

FIG. 18A illustrates an armature having a protrusion for being receivedinto a clip opening to couple a carrier to the armature according to oneimplementation.

FIG. 18B illustrates a cross sectional view of the armature shown inFIG. 18A as viewed through the G-G line.

FIG. 18C illustrates a front perspective view of a carrier for couplingto the protrusion shown in FIGS. 18A and 18B, according to oneimplementation.

FIG. 18D illustrates a rear perspective view of the carrier shown inFIG. 18C.

FIG. 18E illustrates a front view of a clip of the carrier shown in FIG.18C.

FIG. 18F illustrates the carrier shown in FIG. 18C coupled to thearmature shown in FIG. 18A.

FIG. 19A illustrates a perspective view of a push nut for coupling thelens with the carrier according to one implementation.

FIG. 19B illustrates a side view of the push nut shown in FIG. 19A.

FIG. 20 illustrates a light altering film layering arrangement accordingto one implementation.

DETAILED DESCRIPTION

Various implementations disclosed herein include a light bar system fora steering wheel (or grip) of a vehicle. The light bar system includes ahigh intensity light source and a light diffusing layer disposed on aportion of the steering wheel. The light from the light source isdiffused through the light diffusing layer, and the diffused light isemitted toward a driver or operator of the vehicle. For example, incertain implementations, the light bar system includes a plurality ofhigh intensity light emitting diodes (LEDs) disposed behind an outerlens, and the light diffusing layer is a film disposed between an innersurface of the outer lens and the LEDs. In other implementations, theouter lens may diffuse light on its own or in combination with a lightaltering film. The light exiting the outer surface of the outer lensappears as a continuous stream of light across a length of the lens andprovides sufficiently bright lighting to warn or communicate with thedriver in various ambient lighting conditions. In certainimplementations, the outer lens is colored to blend in with the rest ofthe steering wheel when the LEDs are not activated. The outer lensand/or one or more light altering films disposed between the outer lensand the LEDs prevent ambient light from entering the lens andilluminating the LEDs or components behind the lens, which reducesdistractions and the potential for false warnings or unintendedcommunications with the driver.

For example, FIGS. 1 through 4 and 13 and 14 illustrate various aspectsof a light bar system 10 according to one implementation. As shown inFIG. 1, the light bar system 10 is disposed on a front surface 101 of asteering wheel 100, which is the surface that substantially faces adriver of the vehicle. FIG. 2 illustrates a cross-sectional view of thelight bar system 10 along the A-A line in FIG. 1. As shown, the lightbar system 10 includes a printed circuit board (PCB) 20 on which aplurality of light emitting diodes (LEDs) 22 are disposed, a carrier 30that defines a light optimizing channel 32, one or more light alteringfilms 50, an outer lens 40, and a heat transfer pad 60 disposed betweenthe PCB 20 and a rim, or armature, 102 of the steering wheel 100.

FIG. 3 illustrates a front view of the PCB 20 shown in FIG. 2 on whichthe plurality of LEDs 22 are disposed. In this implementation, the PCB20 is substantially arcuate shaped to follow the shape of a portion ofthe front surface 101 of the steering wheel 100. The PCB 20 can include,for example, rigid, semi-rigid, and flexible-type PCBs. In particular,the PCB 20 may include a flex circuit wherein the LEDs 22 are mounted toa backing material that acts as a heat sink. The backing material caninclude, for example, an aluminum flex backing. Other types andcombinations of PCBs are contemplated. The board material of anexemplary PCB 20 may be constructed of FR-4 (G-10) glass reinforcedepoxy laminate. In addition, at least an upper surface of the PCB 20 onwhich the LEDs 22 are disposed may be colored or coated black or anotherdark color to prevent reflection of any ambient light that may passthrough the lens 40.

As shown in FIGS. 2 and 5, the PCB 20 is held in place by a friction fitbetween the carrier 30 and the armature 102. However, in otherimplementations, the PCB 20 may be secured adjacent the armature 102 ofthe steering wheel 100 or carrier 30 using clips, snaps, screws, straps,glue, heat staking, or any other suitable fastening mechanisms. Forexample, in the implementation shown in FIG. 5A, the PCB is securedadjacent the armature using screws, and in the implementation shown inFIG. 12, the screws secure the PCB to a housing that is secured to thearmature. Thus, the PCB may be secured adjacent the armature or adjacentthe carrier or other adjacent components prior to being installedadjacent the armature. Various implementations of assembling thecomponents of the described light bar systems to the steering wheel aredescribed below in relation to FIGS. 15-17.

The LEDs 22 shown in FIG. 3 are top firing LEDs, but side firing LEDsmay be used in other implementations, depending on the contemplated usesof the light bar system and the orientation of the light bar system 10on the steering wheel 100. In addition, the LEDs may be one color,bi-color, tri-color, or multi-color LEDs, and the number of LEDsdisposed on the PCB 20 may be selected based on the arc length of thePCB 20, light intensity desired, size of the steering wheel, and/or thedesign of the light bar system, according to various implementations.For example, in certain implementations, the PCB 20 may include around30 to around 36 LEDs for an arc length equal to about 25% of thecircumference of the steering wheel rim, around 50 LEDs for an arclength equal to about 50% of the circumference of the steering wheelrim, less than 30 LEDs for an arc length less than about 35% of thecircumference of the steering wheel rim, and more than 50 LEDs for anarc length greater than about 50% of the circumference of the steeringwheel rim. For example, in certain implementations, the LEDs 22 may bespaced apart from each other by about 4 to about 13 mm on center alongthe PCB 20, depending on how many LEDs 22 are included and thecontemplated use of the light bar system 10. In other implementations,the PCB 20 may include between 10 and 15 LEDs for an arc length equal toabout 15% to about 25% of the circumference of the steering wheel rim.For example, the PCB 20 may include 11 LEDs for an arc length equal toabout 20% of the circumference of the steering wheel rim.

Furthermore, according to certain implementations, a portion of the LEDs22, such as LEDs 22 a shown in FIG. 3, may include infrared LEDs, and aportion of the LEDs 22, such as 22 b shown in FIG. 3, may includevisible LEDs. The infrared LEDs 22 a may be used to illuminate thedriver's face for cameras that are part of a driver monitoring system ofthe vehicle, for example. The visible LEDs 22 b may have an intensity ofabout 24,000 nits.

The PCB 20 is in electrical communication with an electronic controlunit (ECU) 70, as shown in FIG. 3. The ECU 70 selectively fires the LEDs22 on the PCB 20 based on input from the driver assistance and/or safetysystem(s) of the vehicle (not shown). Various implementations of thisfunctionality are described in co-pending U.S. patent application Ser.No. 14/061,383, filed Oct. 23, 2013, and published as U.S. PatentPublication No. 2014/0111324 on Apr. 24, 2014, which is hereinincorporated by reference in its entirety.

Referring back to FIG. 2, the one or more light altering films 50 mayinclude one or more layers of a brightness enhancing film, a lightdiffusing film, and/or a light turning film. The type(s) of film 50included are selected to assist with diffusing, enhancing, and/orre-orienting or redirecting the light emitted from the LEDs 22 prior tothe light passing through the outer lens 40. In addition, the films 50may be helpful in preventing ambient light from illuminating theinterior components of the system 10. Because the distance between theLEDs 22 and the lens 40 is relatively short, the films 50 are helpful inproviding the desired effect of the light bar system 10 without addingunnecessary bulk to the steering wheel 100. These films may be selectedbased on the desired intensity level and effect. For example, the lightdiffusing film diffuses light passing there through, which causes thelight from individual LEDs to appear as one continuous stream of lightand prevents the appearance of “hot spots” from each individual LED.Brightness enhancing films may be used to increase the intensity of thelight passing through the lens such that the light exiting the lens hasan intensity range desired by consumers and/or manufacturers. Thesebrightness enhancing films may be used to increase the intensity oflight exiting a light diffusing film prior to passing through the outerlens or it may be used to increase the intensity of light from the LEDsprior to the light passing through the outer lens, which may beparticularly useful when the lens is colored and/or translucent andblocks a portion of the light passing through it, according to someimplementations. In addition, the intensity of the LEDs 22 may bereduced, which results in less current and less heat generation by theLEDs 22. To compensate for the reduction in intensity from the LEDs 22,brightness enhancing films may be disposed between the LEDs 22 and theouter lens 40 to increase the intensity of the light prior to the lightexiting the lens 40.

In the implementation shown in FIGS. 2 and 4, the film 50 a is a lightturning film, the film 50 b is a brightness enhancing film, and the film50 c is a light diffusing film. Thus, the light from the LEDs 22 passesthrough the light diffusing film 50 c, then the brightness enhancingfilm 50 b, and then the light turning film 50 a before passing throughthe outer lens 40. In certain implementations, one or more of the films50 may redirect the light to a particular portion of the steering wheelwhere peak intensity is desired. In various other implementations, twoor more layers of the same type of film may be included, one or more ofthe films 50 may be omitted, or all of the films 50 may be omitted,depending on the needs of the light bar system 10. For example, in theimplementation shown in FIG. 20, the system 100 includes a lightdiffusing film 50 c adjacent the LEDs 22 and two layers of a brightnessenhancing film 50 b between the light diffusing film 50 c and the outerlens 40.

In the implementation shown in FIGS. 2 and 13, the carrier 30 may beformed of a plastic or other rigid material and is disposed adjacent thePCB 20 and armature 102. As shown in FIG. 13, the length of the carrier30 is substantially arcuate shaped to follow the shape of a portion ofthe front surface 101 of the steering wheel 100. As shown as FIG. 2, thecarrier 30 includes a base portion 35, two inner side walls 38 a, 38 bthat extend from the base portion 35 toward the front surface 101 of thesteering wheel 100, and two outer side walls 39 a, 39 b that extend fromthe base portion 35 toward the front surface of the steering wheel andare spaced apart from the inner side walls 38 a, 38 b. An outer surfaceof inner side wall 38 a and an inner surface 31 a of outer side wall 39a define an external channel 37 a there between, and an outer surface ofinner side wall 38 b and an inner surface 31 b of outer side wall 39 bdefine an external channel 37 b there between.

The base 35 defines an arcuate shaped hole 24 that is disposed betweenthe inner (or opposing) surfaces of the side walls 38 a, 38 b throughwhich the LEDs 22 may extend, and the inner surfaces of the side walls38 a, 38 b define a light optimizing channel 32. The light optimizingchannel 32 extends from the base 35 toward the outer lens 40. Lightemitted from the LEDs 22 travels through the light optimizing channel 32toward the outer lens 40. The light optimizing channel 32 may have areflective surface, which recycles the light from the LEDs 22 andprevents the light from being diffused prior to reaching a distal end 33of the channel 32. The channel 32 shown in FIG. 2 includes a proximalportion 34 a and a distal portion 34 c that each have a substantiallyrectangular shaped cross-section (as taken through a plane that isperpendicular to the front 101 and rear surfaces of the steering gripand the direction of rotation of the steering wheel 100) and a centralportion 34 b that has a substantially trapezoidal shaped cross-sectionand extends between the proximal and distal portions 34 a, 34 c,respectively. The proximal portion 34 a is disposed adjacent the PCB 20,and the distal portion 34 c is disposed adjacent the distal end 33 ofthe channel 32. The width (as measured in the cross-sectional planedescribed above) of the distal portion 34 c is greater than the width ofthe proximal portion 34 a, and the width of the central portion 34 bincreases from a distal end of the proximal portion 34 a to a proximalend of the distal portion 34 c.

In other implementations, the light optimizing channel may be shapeddifferently. For example, in the implementation shown in FIG. 6, thechannel has a substantially rectangular cross-section between theproximal and distal ends thereof. And, in the implementation as shown inFIG. 7, the channel has a substantially trapezoidal shaped cross sectionextending between the proximal and distal ends thereof. Furthermore, asshown in the implementation shown in FIG. 8, the channel has twoportions that each have a substantially rectangular cross-section of thesame width but are oriented at an angle θ greater than 0° relative toeach other. Other implementations may include alternative suitableshapes depending on the contemplated use of the light bar system and theorientation of the system on the steering wheel. Furthermore, a heightof one side of the channel, as measured between the proximal and distalends of the channel, may be greater than a height of the other side ofthe channel, which may be useful in directing light toward the shorterside of the channel. The implementations in FIGS. 2 and 6 include thisarrangement, for example. However, in other implementations, such asthose shown in FIGS. 7 and 8, the height of each side of the channel maybe substantially the same. For example, in some implementations, theheight of each side of the channel is about 7 to about 10 mm.

In the implementation shown in FIG. 2, the inner surfaces of the sidewalls 38 a, 38 b that define the channel 32 may be coated or treatedwith a reflective material, such as a white or metallic paint, areflective film, or aluminum (or other type of metal) plating, to directthe light from the LEDs 22 toward the outer lens 40. However, in otherimplementations, the side walls that define the light optimizing channelmay be formed from other suitable reflective materials.

The carrier 30 may be disposed adjacent the armature 102 using variousfastening mechanisms, such as screws, clips or snaps, straps, adhesive,or other suitable mechanisms. In the implementation shown in FIGS. 2 and13, the carrier 30 is screwed adjacent the armature 102. In particular,the base 35 of the carrier 30 defines a hole 28 a, 28 b at each endthereof. The hole 28 a, 28 b is configured for receiving a screw (notshown) for securing the carrier 30 adjacent the armature 102. FIGS.5A-5D and FIGS. 18A-18F, which are described below, illustrate otherimplementations in which the carrier is clipped or snapped to thearmature.

FIGS. 18A through 18F illustrate an implementation of carrier 30′ inwhich the carrier 30′ is secured to the armature 102 using a snap fitarrangement. In particular, as shown in FIGS. 18A and 18B, at least oneprotrusion 105 extends from an upper surface 103 of the armature 102.FIG. 18B illustrates a cross sectional view of the armature 102 shown inFIG. 18A as taken through the G-G line. In the example shown in FIG. 18,the protrusion 105 is disposed at the 12 o'clock position on thesteering wheel 100 and extends upwardly from the upper surface 103 ofthe armature. The carrier 30′ includes at least one tab 302 that extendsfrom the base 35′ in a direction opposite inner side walls 37 a′, 37 b′.The tab 302 is disposed inwardly of and spaced apart from the outer sidewall 39 b′ of the carrier 30′. The tab 302 defines an opening 305 thatreceives the protrusion 105 when the carrier 30′ is disposed on thearmature 102 in the intended position. By engaging the protrusion 105into the opening 305, the carrier 30′ is prevented from moving relativeto the armature 102. In other implementations (not shown), the tab 302may define a depression for receiving the protrusion, the tab 302 may bepart of an inner side wall that extends from the base 35′, and/or theopening 305 or depression may be defined in the outer wall 39 b′, whichnegates the need for a separately formed clip 302. And, in otherimplementations, the protrusion may extend from the side wall of thecarrier and the opening or depression for receiving the protrusion maybe defined in the armature. Furthermore, in other implementations, theremay be more than one protrusion and opening or depression and/or theprotrusion may be disposed at a different location on the steering wheel100.

The outer lens 40 shown in FIG. 2 includes a distal end 41 through whichlight enters and exits the lens 40 and side portions 42 a, 42 b thatextend toward the other components of the light bar system 10. Forexample, the lens 40 is substantially U-shaped as viewed in thecross-section taken through the A-A line of FIG. 1, and the distal end41 is disposed between side portions 42 a, 42 b.

The distal end 41 may be partially opaque in certain implementations tomask light from exiting from a portion of the lens 40. The remainingportions of the lens 40 may be translucent and/or colored similarly tothe masked portion to block at least a portion of the light from theLEDs 22 and prevent at least a portion of ambient light from enteringthe lens 40 to keep the components behind the lens 40 hidden from view.By coloring the various portions of the lens 40 similarly, the lensappears as one trim piece and is more aesthetically pleasing. Inaddition, by coloring the lens 40 similarly to the steering apparatus,the lens 40 is not distracting to the driver except when light ispassing through the lens toward the driver. According to certainimplementations, the lens 40 is configured to block at least 90% of thelight that enters the lens. Furthermore, in some implementations, thelens 40 and the light diffusing film may work together to diffuse lightpassing there through to cause the light from individual LEDs to appearas one continuous stream of light and prevents the appearance of “hotspots” from each individual LED. In addition, the lens 40 and the lightdiffusing film may work together to prevent ambient light fromilluminating the interior components of the system.

As shown in FIG. 2, an outer surface 41 a of the distal end 41 follows asubstantially arcuate path as viewed along the A-A line in FIG. 1 suchthat the outer surface 41 a follows the contour of an outer, frontsurface 101 of the steering wheel 100. This shaping also allows the lens40 to blend in with the steering wheel 100 when the LEDs 22 are notexcited by the ECU 70, which may be more aesthetically and ergonomicallypleasing to the driver. In addition, as shown in FIG. 1, a length of theouter surface 41 a of the distal end 41 of the lens 40 follows anothersubstantially arcuate path along a length of the front surface 101 ofthe steering wheel 100.

The lens 40 may be formed of polycarbonate, acrylic, perforatedaluminum, a resin, or other suitable materials. For example, the lens 40may be formed of a resin or other material having light diffusingproperties in some implementations. For example, in certainimplementations in which the lens is formed with material having lightdiffusing properties, the lens may be used with or without the lightdiffusing film. In addition, the lens 40, or at least the outer surface41 a of the distal end 41 thereof, may be dyed or painted to match thesteering wheel color, such as dyed or painted brown or black. Bydarkening at least the outer surface 41 a of the distal end 41 of theouter lens 40, the intensity of the light from the LEDs 22 is reduced toa desired light intensity level. For example, a vehicle manufacturer orconsumer may prefer to have the light intensity level of the lightexiting the lens 40 be between about 500 and about 550 nits for daytimedriving and about 5 nits to about 50 nits during nighttime or lowlighting driving conditions. To achieve the desired light intensitylevels with a dark colored or translucent outer lens, the LEDs 22 may beilluminated at a relatively high intensity level, such as around 24,000nits, to provide sufficient light to be diffused by one or more lightdiffusing films or the outer lens 40, according to certainimplementations. In alternative implementations, the lens may be clear,and one or more light diffusing films 50 c may be disposed between theouter lens 40 and the LEDs 22. Furthermore, the lens 40 and/or the lightdiffusing films 50 c may be configured to block at least about 90% ofthe light.

In addition, according to certain implementations, a portion of the lens40 may be configured to mask, or shape, the light exiting the lens 40.For example, a light blocking paint, dye, or film may be disposed on theinner surface of the lens to block visible light from passing throughthe light blocking paint, dye, or film. For example, the light blockingportion of the lens 40 may be black or brown. This light blockingportion may be disposed above infrared LEDs 22 a on the PCB 20, forexample, or along other portions of the light bar system.

In addition, in some implementations, the lens 40 may be formed usingin-mold labeling (IML) techniques. For example, a film may be printedwith ink that masks light from passing therethrough, and this film isdisposed in a lens mold prior to filling the mold with resin or otherlens-forming material to create the lens. When the lens forming materialis set, the film is cured and integrated with the lens forming materialand becomes the distal outer surface of the lens 40.

The lens 40 may be held in place adjacent the carrier 30 via a frictionfit or it may be fastened in place, such as using screws, clips, glue,straps, or other suitable fastening mechanisms. For example, as shown inFIG. 2, the side portions 42 a, 42 b of the lens 40 extend into theexternal channels 37 a, 37 b, respectively, and may be fastened withinthe respective channel 37 a, 37 b by using a clip, or snap, mechanism.In particular, as shown in FIGS. 13 and 14, the carrier 30 furtherincludes at least one protrusion 26 that extends from the outer surfaceof each inner side wall 38 a, 38 b of the carrier 30 into the channel 37a, 37 b, respectively. Each side portion 42 a, 42 b of the lens 40defines at least one recess or aperture 49 for receiving the respectiveprotrusion 26 when the lens 40 is disposed adjacent the carrier 30. Theengagement of the protrusions 26 into the recesses or apertures 49prevents movement of the lens 40 relative to the carrier 30. Inaddition, as shown in FIG. 13, the base 35 of the carrier defines a posthole 27 a, 27 b at each end that is configured for receiving post 43 a,43 b, respectively, that extend downwardly from the distal end 41 of thelens 40 adjacent each end (along the length thereof) of the lens 40.When the posts 43 a, 43 b are aligned with and engage the post holes 27a, 27 b of the carrier 30, the protrusions 26 and recesses or apertures49 for securing the lens 40 to the carrier 30 are aligned and able toengage.

In a further implementation shown in FIGS. 19A and 19B, one or more pushnuts 215 may be used to prevent the posts 43 a, 43 b from moving axiallyaway from the carrier 30 out of post holes 27 a, 27 b. In particular,each push nut 215 includes an annular shaped base 217 and a plurality ofleaves 219 that extend axially away and radially inwardly from the base217. Each leaf 219 includes a proximal end that is integrally formedwith the base 217 and distal end 221 that extends axially away from thebase 217. The distal ends 221 are separated from each other, are biasedin a radially inward direction toward each other, and define an aperture223.

A lower surface 35 a of the base 35 of the carrier 30 defines a slot 230adjacent each post hole 27 a, 27 b. The base 217 of push nut 215 isslidably engaged into the slot 230 such that the aperture 223 of thepush nut 215 is axially aligned with a respective post hole 27 a, 27 band the distal ends 221 extend away from the lower surface 35 a.Respective posts 43 a, 43 b of the lens 40 are engaged through the postholes 27 a, 27 b and then through aperture 223 of the respective pushnut 215 adjacent the post hole 27 a, 27 b. The radially inwardly biasedleaves 219 prevent the posts 43 a, 43 b from being pulled out of thepost holes 27 a, 27 b in a direction away from the carrier 30.

Alternatively, the protrusions may extend from the inner or outersurface of the side portions 42 a, 42 b of the lens 40, and acorresponding surface within the external channels 37 a, 37 b of thecarrier 30 may define the recesses or apertures configured for receivingthe protrusions. And in yet another alternative implementation (notshown), one or more legs extend from the lower edge of the side portionsof the lens, and each leg includes a protrusion that extends outwardly(or inwardly) toward the side walls 38 a, 38 b or 39 a, 39 b of thecarrier 30. The carrier 30 defines a corresponding aperture or recess inthe base 35 adjacent each external channel 37 a, 37 b, for receivingeach protrusion.

Alternatively or in addition to one or more of the fastening methodsmentioned above, the side portions 42 a, 42 b may be held in the channel37 a, 37 b via a friction fit by tucking edges of the outer skin of thesteering wheel 100 into the channels 37 a, 37 b adjacent the sideportions 42 a, 42 b.

The heat transfer pad 60 is disposed between the PCB 20 and the steeringwheel armature 102 and is configured for dissipating heat generated bythe LEDs 22 on the PCB 20 to the armature 102, which is made of ametallic material and acts as a heat sink. The heat transfer pad 60 isseparately formed from the carrier 30 in the implementation shown inFIG. 2 and may be formed of a thermally conductive resin, a thermallyconductive epoxy, a thermally conductive polymer, a thermally conductivesilicone, a thermally conductive adhesive, a thermal pad, a graphitefilm, and/or a metal. Alternatively (not shown), the heat transfer padmay be integrally formed in at least a portion of a polymeric foammolded layer that is disposed between the armature and the PCB. In suchan implementation, at least the portion of the polymeric foam moldedlayer that is disposed between the PCB 20 and the armature 102 includesa heat conductive material, such as the materials mentioned above, orother suitable thermally conductive material, within the polymeric foammolded layer, and this material dissipates the heat from the PCB 20 tothe armature 102. In addition, in certain implementations, the heattransfer pad 60 is compressible, which allows for greater mechanicalbuild tolerances during assembly of the light bar system 10 onto thearmature 102.

FIG. 5A illustrates another implementation of light bar system 70 inwhich the carrier 80 clips or snaps adjacent the armature 202. FIGS. 5Band 5C illustrate side views of each side of the armature 202 of thesteering wheel 200 as viewed in the C direction and the D direction,respectively, shown in FIG. 5D. Carrier 80 and armature 202 may beclipped together to secure the carrier 80 adjacent the armature 202. Inparticular, the armature 202 includes a central mounting surface 203that substantially faces in the direction of the front of the steeringwheel 200 and side surfaces 204, 205 that extend away from the mountingsurface 203 toward the rear surface of the steering wheel 200 (or in thedirection away from the driver or operator). Heat transfer pad 75 andPCB 92 with LEDs 93 are disposed adjacent the central, mounting surface203.

The carrier 80 includes a base 85 that includes a lower surface 85 athat is disposed adjacent the polymeric foam molded layer 95 and the PCB92 and outer side walls 84 a, 84 b that extend from the base 85 towardthe front surface of the steering wheel 200. Outer surfaces of the outerside walls 84 a, 84 b follow the contour of the steering wheel 200 suchthat the outer covering (or skin) of the steering wheel 200 may bewrapped around the outer surfaces of the outer side walls 84 a, 84 b.Inner side walls 82 a, 82 b extend from the base 85 and are disposedinwardly of and spaced apart from the outer side walls 84 a, 84 b. Innersurfaces of inner side walls 82 a, 82 b define the light optimizingchannel, and outer surfaces of the inner side walls 82 a, 82 b and innersurfaces of the outer side walls 84 a, 84 b define parallel externalchannels. The side portions 42 a, 42 b of the lens 40 and each edge ofthe skin may be tucked within the respective external channels to securethe skin and lens 40 relative to the steering wheel 200.

Each side surface 204, 205 of the armature 202 defines at least onerecess 206, and the recesses 206 are spaced apart axially along thelength of each side surface 204, 205 as shown in FIGS. 5B and 5C. Inaddition, as shown in FIGS. 5B and 5C, the recesses 206 defined on sidesurface 204 are not aligned with the recesses 206 on side surface 205along the arc E that follows the shape of the steering wheel 200 in theplane of its axis of rotation, as shown in FIGS. 5B through 5D. Thus,FIG. 5A only shows recess 206 on side surface 205 because thecross-section shown in FIG. 5A is taken through the B-B line shown inFIGS. 5B through 5D. However, in other implementations, the recesses oneach side surface of the armature may be aligned along the arc followingthe shape of the steering wheel in the plane of its axis of rotation, orthe recesses may include one continuous recess along a portion of eachside surface of the armature.

At least one leg 86 extends from each side of the lower surface 85 a ofthe carrier 80 in a direction away from the front surface of thesteering wheel 200. An inner surface of each leg 86 is disposed adjacentto and is biased toward a respective side surface 204, 205 of thearmature, and a distal end of each leg 86 defines a protrusion 88 thatextends inwardly toward the respective side surface 204, 205 and engagesthe recess 206 when the lower surface 85 a of the base 85 of the carrier80 is disposed adjacent the polymeric foam molded layer 95 and the PCB92.

In addition, other implementations may include a clip mechanism (notshown) in which one or more side surfaces of the armature each defineone or more protrusions that extend outwardly from the respective sidesurface, and the legs of the carrier define one or more recessesconfigured for receiving the protrusions when the carrier is disposedadjacent the armature. Furthermore, in other alternativeimplementations, other fastening mechanisms for securing the carrieradjacent the armature or polymeric foam molded layer may be used, suchas other types of clip mechanisms, snaps, screws, straps, adhesives,and/or heat staking. In the above described implementations, the PCB isdisposed adjacent a heat transfer pad that is disposed directly adjacentthe armature of the steering wheel.

In other various implementations, the carrier defining the lightoptimizing channel may be separately formed from a housing that definesthe outer side walls. For example, FIG. 11 illustrates a light barsystem 150 according to one such implementation. In particular, thehousing 157 and carrier 161 may be formed separately from a plastic orother rigid material. PCB 159 and carrier 161 defining the lightoptimizing channel are disposed within the separately formed housing157, and the housing 157 is disposed adjacent the armature 155. Thearmature 155 may be similar to the implementations described above andincludes a mounting surface 165 that faces the direction of the frontsurface of the steering wheel and side walls 166, 167 that extend fromthe mounting surface 165 in a direction away from the front surface ofthe steering wheel. The housing 157 includes a base 168 that is disposedadjacent the mounting surface 165 and side walls 169, 170 that extendfrom the base 168 toward the front surface of the steering wheel. Outersurfaces of the side walls 169, 170 are arcuate shaped to follow thecontour of the front surface of the steering wheel, and the skin may bewrapped around the outer surfaces of the side walls 169, 170. Innersurfaces of the side walls 169, 170 and the base 168 of the housing 157define a substantially U-shaped channel.

To secure the housing 157 adjacent the armature 155, the base 168 of thehousing 157 defines one or more apertures 172 configured for receiving ascrew 174 there through. One or more apertures 175 defined through themounting surface 165 of the armature 155 align with the apertures 172such that the screw 174 may be engaged through the apertures 172, 175 tosecure the housing 157 to the armature 155. However, in otherimplementations, the housing 157 may be secured adjacent the armature155 using a friction fit or other suitable fastening mechanisms, such asa clip mechanism, such as is described above in relation to FIGS. 5A-5D,straps, adhesives, and/or heat staking, for example.

The carrier 161 includes a base 176, one or more legs 177 that extendfrom a lower surface 176 a of the base 176 in a direction toward thehousing 157 (or away from the front surface of the steering wheel), andside walls 178, 179 that extend from an upper surface 176 b of the base176 in a direction toward the front surface of the steering wheel. Theside walls 178, 179 are disposed inwardly of respective side edges 180,181 of the base 176. The base 176 also defines an aperture 183 throughwhich LEDs 182 disposed on the PCB 159 extend. The base 176 and innersurfaces 184 a, 184 b of the side walls 178, 179, respectively, define alight optimizing channel through which light from the LEDs 182 travelstoward the lens 163.

The carrier 161 and the PCB 159 are disposed within the U-shaped channelof the housing 157 such that the PCB 159 is disposed between the base168 of the housing and the lower surface 176 a of the base 176 of thecarrier 161. To secure the carrier 161 adjacent the housing 157, thelegs 177 of the carrier 161 are clipped, or snapped, into a portion ofthe housing 157. In the implementation shown in FIG. 11, the legs 177include a distal end 186 that is bent inwardly. The base 168 of thehousing 157 defines recesses or apertures 185 through which the distalend 186 of the legs 177 may extend and engage the housing 157 to preventmovement of the carrier 161 relative to the housing 157. However, inother implementations, the distal end may be bent outwardly or maydefine a protrusion configured for engaging the recess or aperture. And,in other implementations (not shown), the side walls 169, 170 of thehousing 157 may define the recesses or apertures. Furthermore, in otherimplementations, protrusions defined by the inner surfaces of the sidewalls 169, 170 of the housing 157 may extend into the U-shaped channel,and these protrusions are configured to engage the upper surface 176 bof the base 176 of the carrier 161 adjacent edges 180, 181.

The PCB 159 is disposed adjacent the base 168 of the housing 157 betweenthe inner surfaces of side walls 169, 170. The PCB 159 is held betweenthe base 168 of the housing 157 and the lower surface 176 a of the base176 of the carrier 161 by a friction fit. However, in otherimplementations, other fastening mechanisms, such as those describedabove, may be used.

In addition, when the carrier is disposed within the U-shaped channel ofthe housing 157, the outer surface of side wall 179 of the carrier 161and the inner surface of the outer walls 169 of the housing 157 define afirst external channel, and the outer surface of side wall 178 of thecarrier 161 and the inner surface of the outer wall 170 of the housing157 define a second external channel. The external channels areconfigured for receiving the skin of the steering wheel and the sideportions of the lens 163, such as is described above in relation to FIG.2.

FIG. 12 is a cross-sectional view similar to the view shown in FIGS. 2and 5A of another implementation of a light bar system 300. The system300 includes similar components as the system 150 shown in FIG. 11, butthe carrier 261 is configured to clip or snap to the PCB 259, and thePCB 259 is screwed onto an upper surface 268 b of the base 268 of thehousing 257. The housing 257 may be secured to the armature (not shown)using any suitable fastening mechanism, such as those described above,or it may include one or more anchoring surfaces (not shown) that extendinto the polymeric foam molded layer and are secured from movingrelative to the armature by the polymeric foam molded layer. The base268 and a portion of the side walls 269, 270 that extend from the base268 of the housing 257 define two substantially parallel channels 275,276 that are recessed relative to the upper surface 268 a of the base268 of the housing 257. Legs 277 extend from the lower surface 278 a ofthe base 278 of the carrier 261, and the distal end 287 of each leg 277is bent inwardly and configured for engaging a lower surface 290 of PCB259. The PCB 259 in this implementation is secured to the base 268 ofthe housing 257 by screws 280 or other suitable fastening mechanisms,such as the fastening mechanisms described above. The parallel channels275, 276 defined by the housing 257 allow the distal end 287 of each leg277 to extend below and engage the lower surface 290 of the PCB 259. Inaddition, the implementation shown in FIG. 12 includes a trim ring thatis disposed between the side portions of the lens 263 and the skin tosecure the lens 263 and skin and to provide a decorative feature on thefront surface of the steering wheel. However, in other implementations,the trim ring may not be included.

According to various implementations, the light diffusing layer and thelight optimizing channel allow less LEDs to be used to achieve thedesired lighting effects, which reduces the amount of power used by thelight bar system and reduces the amount of heat generated by the lightbar system.

The above described implementations include one PCB and one lens.However, in alternative implementations, such as shown in FIG. 9, thesystem may include two or more PCBs and/or two or more outer lens thatare spaced apart from each other along the front surface of the steeringwheel rim. In one alternative implementation, such as is shown in FIG.9, the system includes a first PCB and a first lens disposed adjacentthereto disposed on a first portion of the steering wheel frame between1 and 3 o'clock and a second PCB and second lens disposed adjacentthereto disposed on a second portion of the steering wheel between 9 and11 o'clock. In another alternative implementation, such as shown in FIG.10, the system includes two PCBs 220 a, 220 b arranged in an end to endrelationship along a length of the steering wheel 100 and one lens 240that extends over the LEDs 222 disposed on the PCBs 220 a, 220 b.

Furthermore, various implementations may include other types of lightsources. For example, other types of light sources may include laserdiodes, electroluminescence, organic light emitting diodes (OLEDs), andlight emitting capacitors, according to some implementations. Inaddition, various implementations may include combinations of thevarious types of light sources, light optimizing channels, and lightdiffusing layers described above based on the desired orientation of thelight bar system on the steering wheel, the expected position of theoperator's head relative to the steering wheel, and the contemplateduses of the light bar system. For example, the lens may be angledrelative to a plane that is tangent to the front surface of the steeringwheel to direct light, light directing films may be used to direct lightin a particular direction, and/or the light optimizing channel may beshaped to direct the light in the particular direction.

Various configurations for the various components of light bar systemsand methods of assembling sub-sets of the components are describedabove. FIGS. 15 through 17 illustrate various implementations of methodsof assembling a light bar system to a steering wheel. The stepsdescribed in relation to these methods are intended to encompass variouscombinations of the components and sub-assembly mechanisms describedabove.

In particular, FIG. 15 illustrates a method 1500 of assembling asteering wheel with a light bar system according to one implementation.At step 1501, a heat transfer pad is secured to an armature of thesteering wheel, and in step 1502, a PCB is secured to the pad andarmature. In step 1503, the pad, PCB, and armature are inserted into apolymeric foam molding tool for forming a polymeric foam molded layerover at least the portion of the armature not covered by the PCB andheat transfer pad. In step 1504, a carrier is secured adjacent thearmature such that a light optimizing channel defined by the carrier isadjacent LEDs disposed on the PCB. In step 1505, the lens is securedadjacent the carrier.

FIG. 16 illustrates a method 1600 of assembling the light bar system tothe steering wheel according to one implementation. At step 1601, thearmature is inserted into a polymeric foam molding tool for forming apolymeric foam molded layer over the armature. Then at step 1602, theheat transfer pad is secured to the armature. In step 1603, the PCB issecured to the carrier, and in step 1604, the carrier is secured to thearmature such that the PCB is adjacent the heat transfer pad. In step1605, the lens is secured to the carrier. In an alternativeimplementation, step 1602 may not be necessary if at least the portionof the foam molded layer to be disposed between the PCB and armatureincludes a thermally conductive material within it.

FIG. 17 illustrates a method 1700 of assembling the light bar system tothe steering wheel according to one implementation. At step 1701, theheat transfer pad is secured to the armature, and in step 1702, the PCBis secured to the carrier. In step 1703, the carrier is secured to thearmature such that the PCB is adjacent the heat transfer pad. In step1704, the carrier, pad, PCB, and armature are inserted into a polymericfoam molding tool for forming a polymeric foam molded layer over thearmature and carrier. In step 1705, the lens is secured adjacent thecarrier.

It should be understood that in the implementation described above inrelation to FIGS. 15-17, the carrier may include a carrier that includesan integrally formed housing, such as shown in FIGS. 2-5D and 13, or acarrier that is separately formed from the housing, such as shown inFIGS. 11-12. For implementations in which the carrier is separatelyformed from the housing, the methods above may include the steps (notshown) of securing the housing to the armature, such as prior to steps1504, 1604, and 1703, and securing the carrier to the housing, such asin steps 1504, 1604, and 1703.

In addition, in the implementations shown in the figures describedabove, the light source is disposed below a surface of the lightdiffusing layer that is spaced apart and opposite the layer throughwhich light exits the light diffusing layer. However, in otherimplementations, the light source may be disposed to the side of asurface of the light diffusing layer, such as a surface that is arrangedat about 90° from the light exiting surface of the light diffusinglayer.

While the foregoing description and drawings represent the preferredimplementation of the present invention, it will be understood thatvarious additions, modifications, combinations and/or substitutions maybe made therein without departing from the spirit and scope of thepresent invention as defined in the accompanying claims. In particular,it will be clear to those skilled in the art that the present inventionmay be embodied in other specific forms, structures, arrangements,proportions, and with other elements, materials, and components, withoutdeparting from the spirit or essential characteristics thereof. Oneskilled in the art will appreciate that the invention may be used withmany modifications of structure, arrangement, proportions, materials,and components and otherwise, used in the practice of the invention,which are particularly adapted to specific environments and operativerequirements without departing from the principles of the presentinvention. In addition, features described herein may be used singularlyor in combination with other features. The presently disclosedimplementations are, therefore, to be considered in all respects asillustrative and not restrictive, the scope of the invention beingindicated by the appended claims and not limited to the foregoingdescription.

It will be appreciated by those skilled in the art that changes could bemade to the implementations described above without departing from thebroad inventive concept thereof. It is understood, therefore, that thisinvention is not limited to the particular implementations disclosed,but it is intended to cover modifications within the spirit and scope ofthe present invention, as defined by the following claims.

The invention claimed is:
 1. A light bar system for a steering wheelcomprising: at least one light source disposed adjacent a portion of anarmature of a steering wheel; a carrier defining a light optimizingchannel, the light optimizing channel having a proximal end disposedadjacent the light source; and a light diffusing layer having an innersurface and an outer surface, the inner surface of the light diffusinglayer being disposed adjacent a distal end of the light optimizingchannel, and the light diffusing layer being configured for diffusinglight as it passes therethrough from the inner surface to the outersurface.
 2. The light bar system of claim 1, wherein the light diffusinglayer is configured to cause the light being diffused there through toappear as a continuous stream of light across the light diffusing layer.3. The light bar system of claim 1, wherein the light diffusing layercomprises a light diffusing film.
 4. The light bar system of claim 1,wherein the light diffusing layer comprises an outer lens.
 5. The lightbar system of claim 1, further comprising an outer lens, an outersurface of the outer lens facing a driver and an inner surface of theouter lens facing the light diffusing layer.
 6. The light bar system ofclaim 5, wherein the light diffusing layer is disposed on the innersurface of the outer lens.
 7. The light bar system of claim 5, whereinthe light diffusing layer is a light diffusing film, and the systemfurther comprises one or more additional light altering films disposedbetween the distal end of the light optimizing channel and the innersurface of the outer lens.
 8. The light bar system of claim 7, whereinthe one or more additional light altering films are selected from thegroup consisting of: a brightness enhancing film, a light diffusingfilm, and a light turning film.
 9. The light bar system of claim 8,wherein the one or more additional light altering films comprises abrightness enhancing film, the light diffusing film being disposedadjacent the light optimizing channel and the brightness enhancing filmbeing disposed between the light diffusing film and the lens.
 10. Thelight bar system of claim 9, wherein the one or more additional lightaltering films further comprise a light turning film, the light turningfilm disposed between the brightness enhancing film and the lens. 11.The light bar system of claim 9, wherein the brightness enhancing filmis a first brightness enhancing film and the one or more additionallight altering films further comprises a second brightness enhancingfilm disposed adjacent the first brightness enhancing film.
 12. Thelight bar system of claim 5, wherein the outer surface of the outer lensis disposable in a flush relationship with an outer skin of the steeringwheel.
 13. The light bar system of claim 12, wherein the outer lensfurther comprises side portions that extend from the inner surface ofthe outer lens toward the armature of the steering wheel, the sideportions being configured for securing the outer lens adjacent thearmature.
 14. The light bar system of claim 1, wherein the lightdiffusing layer comprises at least one light diffusing film, and thesystem further comprises an outer lens, wherein the light diffusing filmis disposed between the distal end of the light optimizing channel andan inner surface of the outer lens.
 15. The light bar system of claim 1,wherein the light diffusing layer blocks all ambient light from enteringthe lens.
 16. The light bar system of claim 1, wherein the light sourcecomprises one or more light emitting diodes (LEDs), and the at least oneLED comprises one or more visible light LEDs and one or more infraredlight LEDs.
 17. The light bar system of claim 16, wherein the visiblelight LEDs are disposed adjacent a central portion of the PCB, and theinfrared light LEDs are disposed adjacent each end of the PCB.
 18. Thelight bar system of claim 1, wherein the surface of the light optimizingchannel comprises a reflective coating.
 19. The light bar system ofclaim 1, wherein a foam molded layer is disposed around an armature ofthe steering wheel and at least a portion of the carrier.
 20. The lightbar system of claim 1, wherein the carrier is separately formed from afoam molded layer that is disposed around an armature and is disposedadjacent the armature via one or more fasteners.
 21. The light barsystem of claim 20, wherein the one or more fasteners comprises a clip.22. The light bar system of claim 1, wherein the light source comprisesat least one light emitting diode (LED), and the system furthercomprises a printed circuit board (PCB) on which the at least one LED isdisposed.
 23. The light bar system of claim 22, further comprising aheat transfer pad disposed between the PCB and a steering wheelarmature, the heat transfer pad configured for dissipating heat from thePCB to the steering wheel armature.
 24. The light bar system of claim 1,wherein the light source comprises at least one light emitting diode(LED), and the system further comprises a printed circuit board (PCB) onwhich the at least one LED is disposed and wherein a foam molded layeris disposed around an armature of the steering wheel and a portionthereof comprises at least one thermally conductive material thatconducts heat from the PCB to the steering wheel armature.
 25. The lightbar system of claim 1, wherein the light optimizing channel comprises areflective surface extending between the proximal and distal ends.